Covering element



Aug. 22, 1944', P. G. DEUCHLER covERING ELEMENT Filed Dec. 2k6, 1940 INVENTOR /p Patented Aug. 22, 1944 Cevennes ELEMENT Philip G. Deu-chier, Snyder, N. Y., assigner to Certain-Teed Products Corporation, New N. Y., a corporation of Maryland York,

application December zo, 194e, serial No. 371,799 I (cl. 11i-.5)

4 Claims.

This invention relates to composition covering elements and to processes of making the same. More particularly the invention is directed to the production of thick butt elements of the felt base type which are coated with waterproofing adhesive material and which carry a surfacing of comminuted material embedded in the coating. The element may have an edge of the body thereof divided by slots to form a plurality of tabs and if desired the surfacing carried on the body of the element may be of contrasting appearance. to that upon the tab portions.

VThick butt shingles have been produced by providing a base element with a thicker adhesive coating on the butt or tab portion of the element than upon the body portion thereof. Tapered shingleshave also been produced by providingthe base element. with a coating which. is of gradually decreasing thickness from the butt edge of the element.

Variation in thickness of the coating on the face of the element has been obtained by applying over the entire. face of the element a relatively thick adhesive coating and then doctoring or. scraping away portions of the coating so as to reduce the thickness thereof on the body portions of the element relative to the tab or butt portions. y

Another method by whichv variation of they thickness of coating on the base element has been. secured is by the application of separate coatings of different thickness directly upon dierent portions of. the face of the base element. surfaced with comminuted material of the same or contrasting character upon the body and tab portions of the element.

When contrasting comminuted materials are applied tov differentA portions of the coating on the base element, in carrying out the surfacing operation diiculties have been encountered in securing a sharp line of demarcation between the contrasting areas. This condition may be caused in some cases by the bounce of granules applied to one area, as the granules strike the sheet, across an intended line of demarcation to the adhesive coating to fall upon an adjacent contrasting color area. Spread of the granules to the adjacent area may also be caused by the rolling action of the granules as pressure is applied to embed them in the coating. Unintended delivery of granules to the adjacent area also may be caused by irregularity of flow of the granules fed to the sheet. When the contrasting comminuted material is subsequently ap- In al1 such elements the. coatings may be.

plied. to the'v portion. of the coating which it is. intendedto. surface, it isv prevented from adher ing to the portions accidentally surfaced with the rst granules' and can adhere only tothe portion of the coating not surfaced accidentally or otherwise by these first. applied granules. IntermiXture and interplacement 0f the contrast-l ing materials at or near the intended lineA of demarcation therefore results.

A similar unsatisfactory result. vfrequently 'is'.

obtained if the contrasting surfacing materials are applied simultaneously to the different portions ofv coating on the velementbecause inter?. mixture ofiithe granules of contrasting character. may occur adjacent4 the common boundary asA they move toward the coating 'upon the sheet. n

Insome instances mergingof' the contrasting surfacing materials at their common boundary maynot be objectionable or may even. be considered desirable. However, such merging of color areas is particularlyv objectionable in. the. production of sidingsjwhich are intended to simulate brick units'laid up in mortar. In manufacture of brick simulating siding it is essen-v tial that a clean, sharpline of demarcation be secured between the brick and mortar areas so that a satisfactory representation of brickvvork may be effected. y

Apri'cr art methodof producing thick butt elements bywhich aA sharp line of demarcation.. betweenthe 'contrasting areas may be secured.

is the so-calledjloverlay process. l

in the overlay process the entire surface of the base element is coated with adhesive material and comminuted surfacing materiall is then applied toV the entire coated face and partially embedded in the coating. A second or Voverlay coating of adhesive material is applied to the. surfacing material on the 'portions of the ele* ment intended to be of contrasting appearance. to said first surfacing and a second surfacing of a character contrasting to said first surfacing is applied to the second or overlay coating and par-` tially embedded therein.

Siding which effectively simulatesbrickwork. may be produced by the overlay process because a sharp line of demarcation can be ob tained when the second coating is applied .to

portions of therst orv mortar color surfacingv and thereafter. surfaced. with bri.ck ,color comminuted materia1. However, Vthe comminuted The present invention is directed to a new method of producing thick butt covering elements which is eflicient and economical to carry out.

Another object of this invention is to provide a covering material or an element having areas contrasting in appearance sharply demarked from each other at their common boundary without the disadvantages of the overlay process.

The movement of my invention may be practiced by applying to a base sheet of suitable material a coating of adhesive material so as to cover an entire surface of the sheet. I next apply a comminuted surfacing material to the coating on a limited area of the sheet to leave unsurfaced a portion of said coated sheet. The surfacing is partially embedded in the coating and the excess thereof is removed.

As brought out above, the boundary of the surfaced area may not be sharply demarked from the area intended to be unsurfaced because of bounce of the surfacing over the intended line of demarcation or its uncontrolled delivery to the portionof the coating desired to be kept free of thefirst applied surfacing material.

I next apply a second coating of adhesive material directly tothe area left bare of the first surfacing so as to be superposed upon the first coating and become adhesively bonded thereto. I apply this superposed coating so as to cover the accidental marginaldeposit of surfacing material on the first coating across the intended line of demarcation upon the area intended to be free of said surfacing. I so apply this second coating that a sharp boundary line of coating is formed Where it meetsthe previously surfaced area. This second vcoating may effectively increase the thickness of the portions of the sheet to which it is applied. v

The second or superposed coating is then surfaced with comminuted material contrasting in character to the first applied surfacing material which second surfacing is partially embedded into the superposed coating.

In the product of my invention there is not wasted a substantial quantity of granular surfacing material under the second coating as in the product of the overlay method but there is provided instead an area comprising two coatings bonded-together over the portion of the covering desired to be thickened without the presence of an intermediate layer of granules between the coatings.

Fig. 1 shows an assembly of the siding elements of the invention.

Figs. 2, 3 and 4 show the progressive steps in carrying out'themethod of the invention, Fig. 4 being asection taken on the line 4--4 of Fig. 1.

Fig. 5 is an enlarged section of the butt portion of the element of Fig. 4.

Fig. 6 illustrates the steps in the production of the elements of the invention by a continuous process.

Figl is a modification of the element shown in section in Fig. 4.

Fig. 8 is a further modification of the element shown-in section inFig. 4.

In the assembly of siding elements shown in Fig. 1, each of the elements I comprises a mortar simulating area ID and a plurality of brick simulating areas 9 separated by slots 7.

The.body portion of each of the elements in the area I0 thereof carries a surfacing 4 which may be comminuted mineral material, such as slate granules of mortar color. The areas 8 Qf the tab portion carry a surfacing 6 of brick color which extends from the butt edge of the element a distance to represent the depth of a brick.

A plurality of slots 'l extend from the butt edge of the element a distance equivalent to the thickness of a brick plus the Width of a mortar joint. The slots 1 are equivalent in Width to the usual vertical mortar joint and are spaced apart along the butt edge of the element a distance equivalent'l to the length of the bricks. As a result of the arrangement of the slots a plurality of tabs 8 having brick areas 9 along the butts thereof and between slots 1 are produced on the portion of the element to be exposed to the Weather.

The siding elements l are assembled with the butt edges of the tabs 8 matched to the inner ends of the cut-out slots 1 of the element in the underlying course and arranged with the slots of the successive courses staggered or off-set in order to provide an effective simulation of brick units laid in mortar. y

Figs. 2, 3 and 4 show steps of a process by which the siding elements I of Fig. 1 may be produced.

A base element 2 which may be of felted brous material saturated with a waterproofing material, such as asphalt, is shown in the figures with a coating 3 of adhesive material thereon, such as asphalt which has been applied in heated condition uniformly over a face thereof.

On the area of the body portion of the base 2 vI apply to coating 3 a surfacing 4 of granular material, such as vmineral granules, of suitable mortar color, so as to leave unsurfaced an area of coating 3 the thickness or depth of a brick unit. The area I6 thus is spaced from the butt edge of the elementl approximately the depth of the brick area. I partially embed the granules 4 into the coating 3 and thereafter remove the excess granules from the surface of the element.

In commercial practice it is extremely difcult to control the application of the surfacing 4 on the coating 3 so that only a dened area l0 Will be surfaced therewith because some of the granules such as those indicated at 44 will bounce across the intended line of demarcation or other- Wise become deposited on and partially embedded in the portion of the coating 3 desired to be left bare of mortar color surfacing material 4.

I next apply a layer of` adhesive coating 5 which may be heated asphalt of the same or different character as the coating 3. The coating 5 may be printed directly upon the unsurfaced portion of coating 3 so as to extend from the butt edge of the element 2 across the Width of the tabs a distance equivalent to the depth of a brick unit such as 9. Any accidental deposit of mortar color granules 44 on the coating 3 beside the area l0 will therefore be covered by the superposed coating 5 which becomes united with the coating 3 lying therebeneath.

To the adhesive coating 5 I then apply a surfacing of comminuted material 6, which may be brick color granules, and partially embed the granules 6 into the coating 5 so as to bond them thereto. I then remove the excess granular surfacing 6 from the surface of the element.

Limitation of the brick color granules 6 to the superposed coating 5 need not be attempeted because even if the surfacing 6 were to bounce or accidentally become deposited across the line of demarcation it Would not become secured to the mortar area l0 because the coating 3 on the mortar area I0 has been rendered non-adhesive by the application of the surfacing 4 thereto. A

.clear cut line of. demarcationtherefore-can bejobtaineds between the` surfacing materials IY and 6 on the respective mortar' area I0' and brick areasfS;

Fi'g. 6 illustrates how the; invention may be carried out to produce siding units; in a continuous' manner. It willbe notedi that the Zones IIr III and IV of Fig; 6 correspond to the sections of the element I` of Figs. 2, 3 andl.

A sheet or web of iibrousfelted material l` 2, in the particular embodiment shown of a` width equival'enteto the. transverse to the course width of three elements and of indeiinite length, is carried through a roong machine inthe usual manner.

The portion of the: felted web I2 in zone I has beenpreviously saturated with asphalt and car'- ries a coating of asphalt' I3 in heatedk condition applied uniformly on the surface thereof. The web is then carried" to' suitable surfacing devices where the longitudinal bands' of surfacing i4 of mortar col-or granules. are; applied to the coating I3 on the portions of the web intended to he the mortar' areas I5 in the finished element. As can be seen in zone II. of'Fig. 6, the granules of surfacing I4 although intended to form a sharp line of demarcation with the unsurfaced areas of coating I3 may bounce o-r otherwisebe carried over the intended line of' demarcation and adhere to the adhesive coating on the other side s of said line of demarcation as indicated by the granules IE6. The surfacing I4 is partially embedded in thev coatingv I3 and the excess thereof removed from the' surface of the web.

I next apply in Zone III by suitable means such as a print roll the bands of adhesive coating I5 directly upon the portions of the web carrying the still unsurfaced coating I3v so as to form a sharp line of demarcation where the coating I5 and surfacing I4 meet.

The coating I5 is'applied' so that the surfacing |44 becomes covered bythe coating I5. I preferably slightly overlap the marginal portions of the surfacing I4 with the coating i5 so that meeting of the coating l5 and the surfacing I4 as well as the covering of the granules |44 by the coating I5 is assured even though weaving of the web from side to side occurs as it passes through the machine. Sufticient marginal overlap of the surfacing I5 by the coating I5 may be provided in order to compensate for the greatest amount of side to side movement or weave of the web likely to occur as it is being carried thro-ugh the print rolls for printing coating I5 on the sheet.

As illustrated in zone IV of Fig. 6 the superposed coatinfT I5 is surfaced with brick colored granules I6 and this surfacing is partially embedded in the Coating I5 and the excess thereof removed.

The surfaced web is then fed to suitable cutting apparatus which cuts out the slots II and separates the web along the dotted lines to produce the finished siding elements.

Within the scope of the invention the superposed coatings 5 or I5 may be of the same thickness as the underlying coatings 3 or I3 respectively or may be of greater or less thickness, dependent upon the elect desired.

By the use of asphalt coatings, having a high content of inert or mineral iiiler, I `may apply coatings or substantially greater thickness than would successfully be applied before the development and use of such lled asphalt coating materials in the roofing industry. Such lled coating; may comprise vblown asphalt having incorporated therewith aboutV to' 60% by weight of iine inert `filler material, as for example, ground dolomite limestone, talc, or slate flour.

In Figs. '7 and 8= I have shown sections which illustrate modified lforms which my invention may take when two printed coatings are applied to the portion of the element to be exposed in order to securea thicker butt section.

The element shown in Fig. 7 may be constructed by utilizing the coated and partially surfaced base 2 as sho-wn and described in connection with Fig. 2. Irap-ply the adhesivev coating 25, vsuch as asphalt in heated condition, corresponding to the coating 5 showin. Fig. 4 so as to cover any accidental deposit of granules such as those shown at 4d on the portion of the element to be thickcned. However in `this modification I superpose upon the coating .25 another asphalt coating 2l into. which comminuted material 6 may be partially embedded.

In Fig. 8 I have shown a further modification of my invention by which a sharp line of demarcation rnay be secured at the common boundary 1 of contrasting surfacing material.-

In the modification shown in Fig. 8 the coating corresponding to the coating 3 of Fig. 4 is madeup of two separate portions 23 and 25 applied uponseparate areas of the base 2 so as to form contiguous coatings on the base 2. As illustrated in 8 the .base 2' has an adhesive coating 23,' such as asphalt in heated condition, on a face thereof so limited in extent as to leave an area of the base bare of coating material 23. To the coating 23 I apply comminuted surfacing material ofsuitable appearance, partially embed the same in the coating 23 and remove the excessA thereof from the face of the base. I then print an rasphalt coating -25 directly upon the portions of the base left bare of the coating 23 so as to be contiguous with coating 23 and superpose upon coating t5 another coating 21 of Suitable adhesive material, such; as heated asphalt, so that as to be bonded thereto. I then apply comminuted surfacing material 6 to the coating 21 and partially embed the same therein,

It the embodiments of theinventionshown in Figs. 'Z and 8, are produced in a continuous manner similar to that shown in Fig. 6, I may provide for marginal overlap of the surfacing Il bythe coating 2l as described in connection with Fig. 6 in order to assure meeting of the coating 2 and surfacing i regardlessY of the weave of the sheet as it passes through the machine.

In practicing the above describedr methods of the invention it may be necessary with some coating materials to allow the rst applied adhesive coating to partially or wholly set before a second adhesive coating is superposed directly thereon. When asphalt coating, either filled or unfilled, is applied in heated condition to the base it is usually necessary to allow or cause the first applied coating partially to cool or ccngeal before a second coating of hot asphalt is superposed thereon in order that the two coatings may not merge or run, and thus fail to secure limitation of the printed coating to the areas intended to be covered thereby.

It is to be understood that the foregoing description is merely illustrative of the forms which my invention may take. I do not wish the scope of my invention to be limited to the examples discussed above. For instance, in the element I as shown in Fig. 1, I may omit the slots 'I and use as a base merely a slab having uncut edges. The

surfacing 4 which simulates the mortar color in this case may be carried on the areas occupied by the slots I in the'former embodiment as well as on'the area I0. The coating 5 may be then printed upon the base to represent individual brick units spaced apart along the edge of the element.

My invention is not limited to siding elements simulating brick construction but maybe utilized with any covering material to secure a sharp line of demarcation between contrasting color areas on a base in an efficient manner. Y

Having thus described my invention, I now claim:

1. A thick butt covering element for laying in courses in overlapping arrangement comprising a base sheet, a coating of asphaltic adhesive material in set condition covering a face of said base sheet, a surfacing of comminuted material bonded to and covering a portion of said coating of substantial extent on said face but leaving bare of said comminuted material 'an adjacent portion of said coating of substantial extent on said face, said portions meeting along a common boundary extending coursewise of said element, a second coating of asphaltic adhesive material in set condition superposed directly upon said bare portion of said rst coating and adhesively bonded thereto and overlapping and interlocking with said comminuted surfacing on said first coating only slightly along a narrow portion at said boundary thereof which meetsY said bare portion, said second coating having bonded thereto comminuted surfacing material contrasting in appearance to said comminuted surfacing material which is bonded to said first coating.

2. A thick butt covering element for laying in courses in overlapping arrangement comprising a base sheet of generally rectangular shape having tabs separated by slots in said base extending inwardly from the coursewise edge of said element which is exposed in said arrangement for a substantial distance to form tabs of substantial area, a coating of asphaltic adhesive upon and extending fully over a face of said base, a surfacing of comminuted material bonded to and covering the portion of said coating which extends from a coursewise line adjacent the inner ends of said slots to the edge of the element remote from said coursewise `edge but leaving bare the portion of said coating between said coursewise line and said exposed coursewise edge, a second coating of asphaltic adhesive material in set condition superposed directly upon said bare portion of said first coating and adhesively bonded thereto and overlapping and interlocking with said comminuted surfacing material on said first coating only slightly along a narrow portion at said coursewise line, said second coating having bonded thereto comminuted surfacing material contrasting in appearance to said comminuted surfacing material which is bonded to said first coating.

3. Process-of producing a thick butt covering element forlaying in courses in overlapping arrangement which comprises applying to a base sheet a coating of asphaltic adhesive fully to cover the face of said element, applying to the portion of the area of said coating which is spaced from that coursewise edge of said element which is. exposed in said arrangement a surfacing of comminuted material so as to be bonded to said coating but leaving bare the adjacent portion of the area of said coating which extends between said surfaced portion and said coursewise edge of said element, said'portions both being of substantial extent in the direction transverse to said coursewise direction measured from the boundary therebetween, applying a second coating of asphaltic adhesive upon and directly bonded to said bare portion of said first coating and overlapping and interlocking with said comminuted surfacing material on said first coating only slightly along a narrow portion at said boundary, and applying to said second coating a comminuted surfacing material of contrasting appearance to said comminuted surfacing material which is bonded to said first coating.

4. A process of producing a thick butt covering element which comprises applying to an elongated base sheet a coating of asphaltic adhesive substantially completely to cover said base sheet, applying to bands of substantial width extending lengthwise of said sheet and spaced apart substantial distances widthwise of said sheet comminuted surfacing material so as tobond to said coating and so as to leave bare said space between said bands, applying to said spaces left bare of comminuted surfacing material superposed layers of coating of asphaltic adhesive extending lengthwise of said sheet between said surfaced bands and overlapping and interlocking` with said comminuted surface material on each,

adjacent band only slightly along a narrow portion at the boundary between said surfaced bands and said spaces left bare of comminuted material, applying to said superposed layers of coating comminuted surfacing material contrasting with said first comminuted surfacing material, and cutting said sheets into covering elements with the portions thereof which carry said superposed layer of coating forming the thick butt portions of said elements.

PHILIP G. DEUCHLER.

CERTIFICATE CE CORRECTION. Patent No. 2,556,570. August 22, 19Min PHILIP G a DEUCHIER It is hereby certified that error appears in the printed specification of the above numbered patent requiring eorreeti on as follows: Page 2, first Column, line lO, for the `word "movement" read -improvement; and that the said Letters Patent should be read` with this correction therein that the same may Conform to the record of the Case in the Patent Office.,

signed and Sealed this 7th day of November, A. D. 19ML.

Leslie Frazer (Seal) Acting; Commissioner of Patents. l 

